CN111478465A - Flat wire stator assembly and motor - Google Patents
Flat wire stator assembly and motor Download PDFInfo
- Publication number
- CN111478465A CN111478465A CN202010457756.4A CN202010457756A CN111478465A CN 111478465 A CN111478465 A CN 111478465A CN 202010457756 A CN202010457756 A CN 202010457756A CN 111478465 A CN111478465 A CN 111478465A
- Authority
- CN
- China
- Prior art keywords
- hairpin
- coils
- coil group
- coil
- hair
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Images
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
- H02K1/16—Stator cores with slots for windings
- H02K1/165—Shape, form or location of the slots
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
- H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
- H02K3/28—Layout of windings or of connections between windings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/32—Windings characterised by the shape, form or construction of the insulation
- H02K3/34—Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation
- H02K3/345—Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation between conductor and core, e.g. slot insulation
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/46—Fastening of windings on the stator or rotor structure
- H02K3/50—Fastening of winding heads, equalising connectors, or connections thereto
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
- H02K2203/06—Machines characterised by the wiring leads, i.e. conducting wires for connecting the winding terminations
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K2213/00—Specific aspects, not otherwise provided for and not covered by codes H02K2201/00 - H02K2211/00
- H02K2213/03—Machines characterised by numerical values, ranges, mathematical expressions or similar information
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Windings For Motors And Generators (AREA)
- Manufacture Of Motors, Generators (AREA)
Abstract
The invention discloses a flat wire stator assembly and a motor, which comprise a stator core and stator windings, wherein all hairpin coils are divided into a first hairpin coil group, a second hairpin coil group and a third hairpin coil group, the hairpin coils in the first hairpin coil group are positioned in a first layer, the hairpin coils in the second hairpin coil group are respectively and uniformly distributed in T, T +1, (9) and L-1 layers, the hairpin coils in the third hairpin coil group are positioned in a L layer, the stator windings comprise M parallel sub-windings formed by serially connecting hairpin coils in different mounting grooves with different magnetic poles and different layers, and each sub-winding is formed by serially connecting part or all of the hairpin coils in the first hairpin coil group, the second hairpin coil group and the third hairpin coil group.
Description
Technical Field
The invention relates to the technical field of motor manufacturing, in particular to a flat wire stator assembly and a motor.
Background
In recent years, the electric automobile industry is developed vigorously, the vehicle driving motor is also developed greatly as one of the key parts of the electric automobile, and the performance of the vehicle driving motor is important for the performance of the whole automobile. At present, the motor for the vehicle is developed towards the direction of high speed, light weight and high efficiency, and has higher requirements on the power density, the efficiency level and the heat dissipation capacity of the motor.
Flat wire windings have a higher slot fill factor, higher power density and better heat dissipation than conventional bulk wire windings, and are therefore increasingly used in the field of automotive drive motors. Compared with a scattered wire winding motor, the number of turns of each slot of the flat wire winding motor is small, the number of conductors is 4, 6 and 8, and a plurality of branches are generally connected in parallel for conveniently adjusting the number of turns of each phase in series.
In order to increase the selectable number of turns in series connection in each phase, chinese patent publication No. CN104124803B discloses a bar-wound stator winding arrangement with long-pitch and short-pitch coils, in which, as shown in fig. 2, 6 layers of conductors are divided into 3 sets of windings to form 3 parallel sub-windings, but each parallel branch is connected only between adjacent layers (two layers), and 3 branches have large current imbalance, thereby introducing large additional loss of circulating current and reducing the efficiency in high-speed operation.
In view of the above problems, chinese patent publication No. CN106026435A discloses an electrical device and a stator assembly for the electrical device, in which 6 layers of conductor 3 branches are connected in parallel, wherein 2 branches adopt 1, 2 layers and 5, 6 layers of coils connected in series, the 3 rd branch is 3, 4 layers of coils connected in series, the current imbalance of the parallel branches is weakened, but the current loss still exists, and meanwhile, a complex busbar structure is added, which not only increases the height of the end portion, but also correspondingly increases the cost.
Further, chinese patent publication No. CN107546877A discloses a 6-layer 2-way parallel flat wire stator and motor with each slot, main hairpin wires are distributed in 1/2 layers, 3/4 layers and 5/6 layers, but because there are 2/3 layers and 4/5 layers of jumper hairpin wires, and the outgoing lines thereof are located on the crown side, 2 branch outgoing lines are located on the outermost layer and the innermost layer, and the outgoing lines and the neutral line are both special-shaped lines, the structural shape is complicated, the number of required dies is large in actual production, and the equipment investment cost is increased in batch production.
Disclosure of Invention
In order to overcome the defect that the stator assembly structure in the prior art is complex in forming, the invention provides a flat wire stator assembly. The invention adopts the technical scheme that the flat wire stator component is characterized by comprising the following components: a stator core and at least one stator winding;
the inner wall of the stator core is circumferentially provided with a plurality of mounting grooves, hair-pin coils are inserted in the mounting grooves, conductors in the hair-pin coils in the same mounting groove are sequentially arranged in L layers in an inserting mode, all the hair-pin coils are divided into a first hair-pin coil group, a second hair-pin coil group and a third hair-pin coil group according to different mounting groove positions of straight-line sections of the hair-pin coils, two straight-line sections of the hair-pin coils in the first hair-pin coil group are respectively located at the positions of the first layer of hair-pin coils in the corresponding mounting grooves, two straight-line sections of the hair-pin coils in the second hair-pin coil group are respectively located at the positions of T, T +1, 359, L-1 layers of hair-pin coils in the pair of mounting grooves, L is an even number which is more than or equal to 2, T is an even number which is less than L, and two straight-line sections of the hair-pin coils in the third hair-pin coil group are located at the positions of L layers;
the stator winding comprises M parallel sub-windings formed by serially connecting hairpin coils distributed in different mounting grooves, and each sub-winding is formed by serially connecting part or all of hairpin coils in a first hairpin coil group, a second hairpin coil group and a third hairpin coil group;
and outgoing lines are arranged on the sub-windings and are positioned on the welding side of the stator core, and the outgoing lines are connected to the 1 st layer and the 2 nd layer of the mounting groove, or the L-1 st layer and the L st layer.
Preferably, the number of the slots of the stator core is Z, the number of the stator magnetic poles is 2p, the crown-side span of the hairpin coil of the first hairpin coil group is Z/(2p), the crown-side span of the hairpin coil of the third hairpin coil group includes Z/(2p) +1 and Z/(2p) -1, and the crown-side span of the hairpin coil of the second hairpin coil group is one of Z/(2p) +1, Z/(2p), and Z/(2p) -1.
Preferably, the number of the slots of the stator core is Z, the number of the stator magnetic poles is 2p, the crown-side span of the hairpin coil of the third hairpin coil group is Z/(2p), the crown-side span of the hairpin coil of the first hairpin coil group includes Z/(2p) +1 and Z/(2p) -1, and the crown-side span of the hairpin coil of the second hairpin coil group is one of Z/(2p) +1, Z/(2p), and Z/(2p) -1.
Preferably, the number of the mounting grooves corresponding to one stator magnetic pole in one phase is q, q is an even number greater than or equal to 2, the first hairpin coil group includes q × p hairpin coils, the second hairpin coil group includes q × p (L-2) hairpin coils, and the third hairpin coil group includes q × p hairpin coils.
Preferably, the sub-windings are formed by connecting p × L hairpin coils in series, and each of the sub-windings includes p hairpin coils of the first hairpin coil group, p × L-2 hairpin coils of the second hairpin coil group, and p hairpin coils of the third coil group.
Preferably, the first hairpin coil group comprises first coils with the same number of crown-side spans of Z/(2p) +1 and second coils with the crown-side spans of Z/(2p) -1, the first coils are sleeved outside the second coils to form first coil pairs and are arranged on the stator core, two adjacent first coil pairs are arranged at intervals of Z/p mounting grooves, and the first hairpin coil group of each phase is adjacent to Z/m/p mounting grooves;
the second hairpin coil group comprises hairpin coils with unique span, the hairpin coils with two spaced mounting grooves are used as second coil pairs and are arranged on the stator core, every two adjacent second coil pairs are arranged at intervals of Z/2/p mounting grooves, and every two adjacent second hairpin coil groups are adjacent to Z/m/p mounting grooves;
the third hairpin coil group comprises hairpin coils with unique span, two hairpin coils in two adjacent mounting grooves are used as a third coil pair and are arranged on the stator core, two adjacent third coil pairs in each phase are arranged at intervals of Z/p mounting grooves, and the third hairpin coil group in each phase is adjacent to Z/p mounting grooves.
Preferably, the sub-winding lead-out wires of each phase are connected in a Y shape or a delta shape.
Preferably, the number M of the sub-windings is equal to the number q of the mounting slots corresponding to one stator magnetic pole in one phase, q is an even number greater than or equal to 2, the number of phases of the motor is M, and q = Z/(2 mp).
Preferably, after all the hairpin coils are inserted into the mounting groove, a crown side is formed at one end of the stator core, a welding side is formed at the opposite end of the stator core, the hairpin coils located in the odd-numbered layers of the mounting groove are twisted in one direction, the hairpin coils located in the even-numbered layers are twisted in the other direction, and the ends of the hairpin coils between different layers are sequentially welded to realize electrical connection.
The invention also provides a motor which comprises the flat wire stator assembly and the rotor assembly.
Compared with the prior art, the invention has the following beneficial effects:
1. each hairpin coil in each parallel sub-winding of each phase is uniformly distributed at the position of different layers in each pole mounting groove, so that the counter potentials and currents of the parallel sub-windings are completely the same, and the additional copper loss of stator winding circulation caused by parallel connection of the sub-windings is eliminated, thereby improving the high-speed efficiency of the motor, ensuring the temperature uniformity of the stator winding and further prolonging the service life of the motor;
2. the leading-out wires at the head and tail positions of the parallel sub-windings are positioned at adjacent positions, so that the complexity of the Busbar is greatly simplified, the reliability of the Busbar is improved, the using amount of neutral copper bars is reduced, injection molding materials are saved, and the height of the end part is reduced, so that the material cost and the manufacturing cost of the whole stator assembly are reduced;
3. the line type of the crown side hairpin coil is greatly reduced, and meanwhile, the outgoing line is positioned at the welding side, so that a special-shaped Ipin line and a special-shaped neutral line do not exist, and the overall structure is simplified; if the die is adopted for forming, the number of forming dies and the number of forming devices of the hairpin coil are reduced, and if the manipulator is adopted for bending, the number of bending machines is reduced, and finally the input cost of manufacturing equipment is reduced;
4. the hairpin coils of each layer are mutually independent, and no extra cross-layer hairpin line exists, so that full-automatic wire plugging can be realized through the independent wire cups, the manufacturing process is simplified, and the large-batch production is facilitated.
Drawings
The invention is described in detail below with reference to examples and figures, in which:
FIG. 1 is a schematic structural diagram of a stator assembly according to a first embodiment;
FIG. 2 is a diagram of three parallel sub-winding connections;
FIG. 3 is a schematic cross-sectional view of a stator and rotor of an electric machine;
FIG. 4 is a schematic cross-sectional view of a hairpin coil;
FIG. 5 is a schematic view of the mounting slot and conductors within the slot;
FIG. 6 is a diagram illustrating a card sending coil structure of a first card sending coil set according to an embodiment;
FIG. 7 is a schematic diagram of a first hairpin coil assembly;
FIG. 8 is a structural diagram of a second hairpin coil set;
FIG. 9 is a schematic diagram of a second hairpin coil set;
FIG. 10 is a schematic diagram of a third hairpin coil set hairpin coil configuration;
FIG. 11 is a schematic diagram of a third hairpin coil group;
fig. 12 is a schematic structural diagram of a U-phase first parallel sub-winding unit;
FIG. 13 is a schematic of a three-phase winding connection;
FIG. 14 is a schematic diagram showing the arrangement of the hairpin coils in the stator winding mounting slots of the three phases in the first embodiment;
FIG. 15 is a schematic diagram of the electrical connection of a three-phase lead-out wire;
FIG. 16 is a diagram showing a card sending coil structure of the first card sending coil set according to the second embodiment;
fig. 17 is a schematic layout diagram of the hairpin coils in the mounting slots of the three-phase stator windings in the third embodiment.
2. A stator core; 3. welding the side; 4. an outgoing line; 5. neutral copper bars; 6. insulating paper; 7. lateral crown; stator assembly C1; rotor assembly C2; conductor a 1; an insulating layer a 2; a first hairpin coil group T1; a second hairpin coil group T2; a third hairpin coil group T3; a first coil T11; the second coil T12; u-phase first parallel sub-winding P1.
Detailed Description
A flat wire stator assembly comprises a stator core 2 and at least one stator winding, as shown in figure 1, Z mounting grooves are formed in the inner wall of the stator core 2 along the circumferential direction, hairpin coils are inserted in the mounting grooves, a plurality of hairpin coils in the same mounting groove are arranged in L layers in a splicing mode (L is an even number larger than or equal to 2), all the hairpin coils are divided into a first hairpin coil group T1, a second hairpin coil group T2 and a third hairpin coil group T3 according to different positions in the mounting grooves, as shown in figures 2 and 3, the stator winding comprises M sub-windings, and each sub-winding is formed by connecting part or all of the hairpin coils in the first hairpin coil group T1, the second hairpin coil group T2 and the third hairpin coil group T3 in series.
The mounting grooves are through rectangular grooves, each rectangular groove is provided with insulating paper 6 for ensuring electrical insulation between the hairpin coil and the stator core 2, the hairpin coil is made of a flat wire, and as shown in fig. 4, the section of the hairpin coil is a rectangular conductor a1 and an insulating layer a2 is coated outside the conductor a 1.
The two straight line sections of the hairpin coils in the first hairpin coil group T1 are positioned in the first layer of a pair of mounting grooves, the two straight line sections of the hairpin coils in the second hairpin coil group T2 are respectively and uniformly distributed in the T, T +1, the T and the L-1 layers of the pair of mounting grooves, L is an even number which is more than or equal to 2, T is an even number which is less than L, the two straight line sections of the hairpin coils in the third hairpin coil group T3 are positioned in the L layers of the pair of mounting grooves, and the sub-winding is formed by serially connecting a plurality of hairpin coils which are distributed in different mounting grooves and have different magnetic poles and different layers.
The stator assembly ensures that the counter potentials of the parallel sub-windings are completely the same and the circulation between the parallel sub-windings is completely eliminated by uniformly distributing the hairpin coils, which are connected in series with the parallel sub-windings and are contained in the stator windings of each phase, under different poles of different layers of the stator slot, thereby reducing the additional copper consumption of the circulation in high-speed operation and ensuring the uniformity of the temperature rise of the inner layer and the outer layer of the stator winding.
For convenience of description, the stator assembly is applied to an M-phase motor, the number of mounting slots formed in the stator core 2 is Z, the number of stator magnetic poles is 2p (p is a positive integer), L layers (L is an even number equal to or greater than 2) are wound in the mounting slots, q (q is an even number equal to or greater than 2) is formed in each phase of each pole, the number of parallel sub-windings is M = q, in this embodiment, M =3, Z =48, p =4, L =4, q = Z/(2mp) =2, and M = q = 2.
As shown in fig. 5, when the three-phase stator winding is wound into 4 layers in the mounting slots of the stator core 2, that is, each mounting slot of the stator core 2 has 4 conductors, which are sequentially identified as a first layer L, a second layer L, a third layer L and a fourth layer L from outside to inside along the radial direction of the motor, each first hairpin coil set T1 includes q × p =8 hairpin coils, each second hairpin coil set T2 includes q × p (L-2) =16 hairpin coils, each third hairpin coil set T3 includes q × p =8 hairpin coils, and the flat-wire stator assembly includes three stator windings altogether, each stator winding corresponds to one phase and is composed of 2 parallel sub-windings, each parallel sub-winding in each phase is composed of p L =16 coils connected in series, and each parallel sub-winding includes 4 hairpin coils of the first hairpin coil set T1, a second hairpin coil set T8298 and a third hairpin coil set L.
Specifically, the hairpin coil of the first hairpin coil group T1 is a full pitch coil having a crown side 7 span of Z/(2p) =6, the hairpin coil of the third hairpin coil group T3 is a long span coil having a crown side 7 span of Z/(2p) +1=7 and a short span coil having a span of Z/(2p) -1=5, and the hairpin coil of the second hairpin coil group T2 may be one of a crown side 7 span of Z/(2p) +1=7, Z/(2p) =6, and Z/(2p) -1= 5. Of course, the hairpin coils in the sub-windings have various different combinations, and in another embodiment, the hairpin coil of the third hairpin coil group T3 may be a full-pitch coil with a crown side 7 span of Z/(2p) =6, the hairpin coil of the first hairpin coil group T1 may be a long-span coil with a crown side 7 span including Z/(2p) +1=7 and a short-span coil with Z/(2p) -1=5, and the hairpin coil of the second hairpin coil group T2 may be one of a crown side 7 span of Z/(2p) +1=7, Z/(2p) =6, Z/(2p) -1= 5.
In the present embodiment, as shown in fig. 6 and 7, the first hairpin coil group T1 includes 12 same first coils T11 whose crown side 7 spans Z/(2p) +1=7 and second coils T12 whose crown side 7 spans Z/(2p) -1=5, which are distributed in three phases, so that each phase includes 4 first coils T11 and 4 second coils T12. The first coil T11 is similar to the second coil T12 in structure, and differs from the second coil T12 only in the span, for example, the first coil T11 includes bent portions B10 and B14, straight line portions B11 and B13 inserted into the mounting groove, and a two-straight-line-portion connecting portion B12, and is U-shaped as a whole, and the straight line portions B11 and B13 are located in the mounting groove, in the same layer, and in the first layer.
Straight line sections B11 and B13 of the first coil T11 are inserted into the mounting grooves from one axial side of the stator core 2 and are bent in the same direction from the other axial side of the stator core 2, so that bent sections B10 and B14 are formed, the number of crossing stator slots formed by connecting sections B12 between straight line sections B11 and B13 forms a span of a crown side 7, one end of the stator core 2 close to the bent sections is a welding side 3, and the other end of the stator core 2 is a crown side 7. Of course, the first hairpin coil group T1 may also include three hairpin coils having crown side 7 with spans of 5, 6, and 7, respectively.
The first coil T11 is sleeved on the second coil T12, the first coil T11 is arranged on the stator core 2 in pairs, two adjacent first coils T11 in each phase are arranged in pairs of mounting grooves at intervals of Z/p =12, and the first hairpin coil group T1 in each phase is arranged in pairs of mounting grooves at intervals of Z/m/p =4, that is, the U-phase, V-phase and W-phase stator windings respectively have 4 mounting grooves.
As shown in fig. 8 and 9, the single hairpin coil of the second hairpin coil group T2 includes bent portions B10 and B14, straight line portions B11 and B13 inserted into the mounting groove, and a two-straight line portion connecting portion B12, which are U-shaped as a whole, the straight line portions B11 and B13 of the second hairpin coil group T2 coil are inserted into the mounting groove from one side in the axial direction of the stator core 2, and bent in opposite directions from the other side in the axial direction of the stator core 2, thereby forming bent portions B10 and B14, the straight line portions B11 and B13 are respectively located in layers L2 and L3 in the mounting groove (L =4, T = 2), and the crown side 7 formed by the connecting portion B12 between the straight line portions B11 and B13 is one of 5, 6, and 6 in this embodiment.
The three-phase second hairpin coil group T2 is composed of 48 (m × q × p (L-2) =48) hairpin coils, corresponding to 16 (q × p (L-2) =16) hairpin coils per phase, the hairpin coils with two spaced mounting slots are arranged on the stator core 2 as a pair of second coils T12, two adjacent second coils T12 of each phase are arranged with Z/2/p =6 mounting slots, and the second hairpin coil group T2 of each phase is adjacent to Z/m/p =4 mounting slots, that is, the U-phase, V-phase and W-phase stator windings have 4 mounting slots respectively.
As shown in fig. 10 and 11, the third hairpin coil group T3 has a single coil including bent portions B10 and B14, straight line portions B11 and B13 inserted into the mounting groove, and two straight line connecting portions B12, and is U-shaped as a whole. The straight line portions B11 and B13 of the coils of the third hairpin coil group T3 are inserted into the mounting grooves from one side in the axial direction of the stator core 2, and bent in the same direction in the other side in the axial direction of the stator core 2, thereby forming bent portions B10 and B14, and the crown side 7 formed between the straight line portions B11 and B13 by the connecting portion B12 spans an integer of 6.
The three-phase third hairpin coil group T3 is composed of 24 hairpin coils, corresponding to 8 hairpin coils in each phase, and two hairpin coils in two adjacent mounting grooves are arranged on the stator core 2 as a third coil pair, the two adjacent third coil pairs in each phase are arranged at an interval of Z/p =12 mounting grooves, the three-phase third hairpin coil group T3 in each phase is adjacent to Z/p =4 mounting grooves, that is, the U-phase, V-phase and W-phase stator windings differ by 4 mounting grooves, respectively.
Because each phase of stator winding is the same, only 4 slots different in arrangement are arranged in the installation slot, and the U-phase is used for explaining the composition of each parallel sub-winding. As shown in fig. 12, the first parallel sub-winding of the U-phase has 16 coils, and is formed by connecting 4 second coils T12 in the first hairpin coil group T1, 8 hairpin coils in the second hairpin coil group T2, and 4 hairpin coils in the third hairpin coil group T3 in series. The U-phase second parallel sub-winding comprises 16 coils which are composed of 4 first coils T11 in the first hairpin coil group T1, 8 hairpin coils in the second hairpin coil group T2 and 4 hairpin coils in the third hairpin coil group T3.
In addition, the U-phase first parallel sub-winding P1 may also be composed of 4 first coils T11 in the first hairpin coil group T1, 8 hairpin coils in the second hairpin coil group T2, and 4 hairpin coils in the third hairpin coil group T3. The second parallel sub-winding is composed of 4 second coils T12 in the first hairpin coil group T1, 8 hairpin coils in the second hairpin coil group T2, and 4 hairpin coils in the third hairpin coil group T3.
As described above, after the hairpin coils of each phase are inserted into the stator slots from one axial side of the stator core 2, the other axial side of the stator core 2 is bent and twisted, the bending and twisting is performed by the twisting die, the odd-numbered layers are twisted in one direction, the even-numbered layers are twisted in the other direction to form the hairpin coil bent portions, the first hairpin coil group T1 bent portion is electrically connected to the corresponding second hairpin coil group T2 bent portion by welding, the second hairpin coil group T2 bent portion is electrically connected to the corresponding third hairpin coil group T3 bent portion by welding, the number of stator slots spanned by the two welded portions forms a welding side 3 span, the welding side 3 span may be one of 5, 6, and 7, and the welding may be performed by TIG welding, plasma welding, laser welding, or the like.
After welding is completed, the sub-windings form the minimum unit of electrical connection, at this time, the head and tail outgoing lines 4 of each parallel sub-winding are located on the welding side 3 and are located on the first layer, the second layer, or the third layer and the fourth layer, the outgoing lines 4 of two parallel sub-windings in the same stator winding are combined into one, and then the stator assembly of the three-phase motor has three outgoing lines 4 in total, as shown in fig. 15, the three outgoing lines 4 are connected into a Y shape or a delta shape through the neutral copper bar 5.
Because the lead-out wire 4 of two adjacent sub-windings merges into one, three last lead-out wires 4 of three-phase stator module all are located welding side 3 and can directly connect the terminal to draw forth to simplified the Busbar complexity greatly, improved its reliability, reduced 5 quantity of neutral copper bars simultaneously, and saved the material of moulding plastics, reduced the tip height, and then reduced whole stator module material cost, manufacturing cost.
On the other hand, the hairpin coil needs to be obtained through die stamping or is bent through a manipulator, but although the die stamping mode is high in precision and efficiency, an additional die needs to be opened, and the manipulator bending mode is poor in forming precision, relatively low in efficiency and good in flexibility.
In this scheme, as shown in fig. 13 and 14, the stator winding is composed of 2 kinds of hairpin coils in the first hairpin coil, 1 kind of hairpin coil in the second hairpin coil group T2, and 1 kind of hairpin coil in the third hairpin coil group T3, totally 4 kinds of hairpin coils, the hairpin coil type is greatly reduced, if the mold forming mode is adopted, thereby reducing the number of hairpin forming molds, for batch production, the investment of forming equipment or bending equipment can be reduced, and further the production cost is reduced. Meanwhile, the three hairpins of the first hairpin coil group T1, the second hairpin coil group T2 and the third hairpin coil group T3 are independent of one another, extra crossed cross lines do not exist, full-automatic wire plugging can be achieved through independent wire cups, and mass production efficiency is greatly improved.
As a second embodiment of the present invention, another flat wire stator assembly is disclosed, as shown in fig. 16, which is different from the above-described embodiments in that the first hairpin coil group T1 includes 7 hairpin coils of three spans on the crown side, the first hairpin coil group T1 is composed of 24 hairpin coils, and includes 6 first hairpin coil groups T1, a first coil group T11, 6 first hairpin coil groups T1, a second coil group T12, and 12 first hairpin coil groups T1, third coils. The first coil T11 corresponding to each phase, the second coil T12 corresponding to each phase, and the third coil T1 corresponding to each phase respectively comprise 2 first hairpin coil groups T1, 2 first hairpin coil groups T1, and 4 first hairpin coil groups T1, and the span of the third coil is 6.
The three-phase second hairpin coil group T2 is the same as the first embodiment, the span of the crown side 7 is one of 5, 6 and 7, and the crown side is composed of 48 hairpin coils, corresponding to each phase, that is, each phase contains 16 hairpin coils of the second hairpin coil group T2; the three-phase third hairpin coil group T3 is the same as in the first embodiment, and the crown side 7 has a span of 6, and is composed of 24 hairpin coils, corresponding to each phase, that is, each phase contains 8 hairpin coils of the third hairpin coil group T3.
As an embodiment three of the present invention, another flat wire stator assembly is disclosed, as shown in fig. 17, which is different from the first embodiment in that 8 layers of flat wire conductors are arranged in slots as shown in fig. 17, L =8, that is, 8 layers of flat wire conductors are arranged in slots, two straight line segments of the hairpin coils in the first hairpin coil group T1 are located in the same layer and are located in the first layer, two straight line segments of the hairpin coils in the second hairpin coil group T2 are located in 2, 3, 4, 5, 6, 7 layers, two straight line segments of the hairpin coils in the third hairpin coil group T3 are located in the same layer and are located in the 8 th layer, the three-phase first hairpin coil group T1 is composed of 24 hairpin coils, including the first coils T11 of 12 first hairpin coil groups T68 and the second coils T2 of 12 first hairpin coil groups T1, the second hairpin coil group T2 is composed of 24 hairpin coils, including the first hairpin coils T3526, the third hairpin coils T49348, the third hairpin coil group T2 is located in 3, 6 layers, and 48 layers are located in the third hairpin coil layers 49348.
From the first and third embodiments, when the number of hairpin coils in the mounting groove is 4, the stator winding is composed of 2 hairpin coils in the first hairpin coil, 1 hairpin coil in the second hairpin coil group T2, and 1 hairpin coil in the third hairpin coil group T3, and includes 4 different types of hairpin coils in total; when the number of the hairpin coils in the mounting groove is 6, the stator winding consists of 2 hairpin coils in the first hairpin coil, 2 hairpin coils in the second hairpin coil group T2 and 1 hairpin coil in the third hairpin coil group T3, and the stator winding comprises 5 hairpin coils of different types in total; when the number of the hairpin coils in the mounting groove is 8, the stator winding consists of 2 hairpin coils in the first hairpin coil, 3 hairpin coils in the second hairpin coil group T2 and 1 hairpin coil in the third hairpin coil group T3, and the stator winding totally comprises 6 hairpin coils of different types. Therefore, statistics shows that by adopting the technical scheme of the invention, the types of the hairpin coils are greatly reduced, and the bending forming and batch processing efficiency of the die is greatly improved.
The invention also discloses a motor, which can be applied to automobile driving and comprises a rotor assembly C2 and the stator assembly C1 as shown in figure 3.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents and improvements made within the spirit and principle of the present invention are intended to be included within the scope of the present invention.
Claims (10)
1. A flat wire stator assembly, comprising: a stator core and at least one stator winding;
the inner wall of the stator core is circumferentially provided with a plurality of mounting grooves, hair-pin coils are inserted in the mounting grooves, conductors in the hair-pin coils in the same mounting groove are sequentially arranged in L layers in an inserting mode, all the hair-pin coils are divided into a first hair-pin coil group, a second hair-pin coil group and a third hair-pin coil group according to different mounting groove positions of straight-line sections of the hair-pin coils, two straight-line sections of the hair-pin coils in the first hair-pin coil group are respectively located at the positions of the first layer of hair-pin coils in the corresponding mounting grooves, two straight-line sections of the hair-pin coils in the second hair-pin coil group are respectively located at the positions of T, T +1, 359, L-1 layers of hair-pin coils in the pair of mounting grooves, L is an even number which is more than or equal to 2, T is an even number which is less than L, and two straight-line sections of the hair-pin coils in the third hair-pin coil group are located at the positions of L layers;
the stator winding comprises M parallel sub-windings formed by serially connecting hairpin coils distributed in different mounting grooves, and each sub-winding is formed by serially connecting part or all of hairpin coils in a first hairpin coil group, a second hairpin coil group and a third hairpin coil group;
and outgoing lines are arranged on the sub-windings and are positioned on the welding side of the stator core, and the outgoing lines are connected to the 1 st layer and the 2 nd layer of the mounting groove, or the L-1 st layer and the L st layer.
2. The flat wire stator assembly of claim 1, wherein the number of stator core slots is Z, the number of stator poles is 2p, the crown-side span of the hairpin coils of the first hairpin coil group is Z/(2p), the crown-side span of the hairpin coils of the third hairpin coil group includes both Z/(2p) +1 and Z/(2p) -1, and the crown-side span of the hairpin coils of the second hairpin coil group is one of Z/(2p) +1, Z/(2p) -1.
3. The flat wire stator assembly of claim 1, wherein the number of stator core slots is Z, the number of stator poles is 2p, the crown-side span of the hairpin coils of the third hairpin coil group is Z/(2p), the crown-side span of the hairpin coils of the first hairpin coil group includes both Z/(2p) +1 and Z/(2p) -1, and the crown-side span of the hairpin coils of the second hairpin coil group is one of Z/(2p) +1, Z/(2p) -1.
4. The flat wire stator assembly of claim 2 or 3, wherein the number of slots corresponding to one stator pole in one phase is q, q is an even number greater than or equal to 2, the first hairpin coil group includes q x p hairpin coils, the second hairpin coil group includes q x p (L-2) hairpin coils, and the third hairpin coil group includes q x p hairpin coils.
5. The flat wire stator assembly of claim 4, wherein the sub-windings are comprised of p x L hairpin coils in series, and each includes p hairpin coils of a first hairpin coil set, p x (L-2) hairpin coils of a second hairpin coil set, and p hairpin coils of a third coil set.
6. The flat wire stator assembly of claim 3, characterized in that the first hairpin coil group includes the same number of first coils with crown-side span Z/(2p) +1 and second coils with crown-side span Z/(2p) -1, the first coils are sleeved outside the second coils to form first coil pairs arranged on the stator core, each two adjacent first coil pairs are arranged with Z/p mounting slots, the first hairpin coil group of each phase is adjacent to Z/m/p mounting slots;
the hairpin coils in the second hairpin coil group have unique span, the hairpin coils in two adjacent mounting grooves are used as second coil pairs and are arranged on the stator core, each two adjacent second coil pairs are arranged at intervals of Z/2/p mounting grooves, and the second hairpin coil groups of each phase are adjacent to Z/m/p mounting grooves;
the third hairpin coil group comprises hairpin coils with unique span, two hairpin coils in two adjacent mounting grooves are used as a third coil pair to be arranged on the stator core, each two adjacent third coil pairs are arranged at intervals of Z/p mounting grooves, and the third hairpin coil group of each phase is adjacent to Z/m/p mounting grooves.
7. The flat wire stator assembly of claim 6 wherein the phase sub-winding lead-outs are connected in a Y-or delta-shape.
8. The flat wire stator assembly of claim 1 wherein the number of sub-windings M is equal to the number of slots q for one stator pole in a phase, q is an even number greater than or equal to 2, the number of phases of the machine is M, and q = Z/(2 mp).
9. The flat wire stator assembly of claim 7, wherein after all of said hairpin coils are inserted into said slots, a crown side is formed at one end of said stator core, and a welding side is formed at the opposite end, wherein straight line segments of all of said hairpin coils at one end of said welding side are located in odd-numbered layers of said slots and twisted in one direction, hairpin coils located in said even-numbered layers are twisted in the other direction, and the ends of hairpin coils between different layers are welded in sequence to achieve electrical connection.
10. An electrical machine comprising the flat wire stator assembly and rotor assembly of any of claims 1-9.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202010457756.4A CN111478465A (en) | 2020-05-26 | 2020-05-26 | Flat wire stator assembly and motor |
| PCT/CN2020/117206 WO2021237991A1 (en) | 2020-05-26 | 2020-09-23 | Flat wire stator assembly and motor |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202010457756.4A CN111478465A (en) | 2020-05-26 | 2020-05-26 | Flat wire stator assembly and motor |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN111478465A true CN111478465A (en) | 2020-07-31 |
Family
ID=71765329
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202010457756.4A Pending CN111478465A (en) | 2020-05-26 | 2020-05-26 | Flat wire stator assembly and motor |
Country Status (2)
| Country | Link |
|---|---|
| CN (1) | CN111478465A (en) |
| WO (1) | WO2021237991A1 (en) |
Cited By (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2021237991A1 (en) * | 2020-05-26 | 2021-12-02 | 上海威迈斯新能源有限公司 | Flat wire stator assembly and motor |
| CN113783334A (en) * | 2021-09-06 | 2021-12-10 | 恒大新能源汽车投资控股集团有限公司 | Flat wire armature winding and motor |
| CN114079343A (en) * | 2020-08-21 | 2022-02-22 | 比亚迪股份有限公司 | Stator assembly and motor with same |
| CN114301199A (en) * | 2021-12-31 | 2022-04-08 | 苏州汇川联合动力系统有限公司 | Stator assembly and motor |
| CN114337009A (en) * | 2021-11-12 | 2022-04-12 | 浙江零跑科技股份有限公司 | Stator module, motor and electric automobile |
| CN114337010A (en) * | 2021-12-31 | 2022-04-12 | 苏州汇川联合动力系统有限公司 | Stator module and motor |
| CN114583863A (en) * | 2021-12-31 | 2022-06-03 | 华为数字能源技术有限公司 | Stator, flat wire motor, power assembly and vehicle |
| WO2023201960A1 (en) * | 2022-04-22 | 2023-10-26 | 上海纳铁福传动系统有限公司 | Stator winding and motor |
| WO2024007713A1 (en) * | 2022-07-06 | 2024-01-11 | 浙江凌昇动力科技有限公司 | Stator, flat wire motor, powertrain, and vehicle |
| WO2024007438A1 (en) * | 2022-07-04 | 2024-01-11 | 合肥巨一动力系统有限公司 | Stator structure of hairpin motor |
| WO2024060734A1 (en) * | 2022-09-21 | 2024-03-28 | 丽水方德智驱应用技术研究院有限公司 | Stator assembly based on flat wire segmented skewed slot winding |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114552810B (en) * | 2022-01-21 | 2023-08-01 | 浙江零跑科技股份有限公司 | Stator assembly, motor with same and vehicle |
| CN114977559B (en) * | 2022-06-28 | 2024-04-02 | 蜂巢传动系统(江苏)有限公司保定研发分公司 | Motor winding, motor stator assembly and motor |
| CN115459496A (en) * | 2022-10-28 | 2022-12-09 | 智新科技股份有限公司 | Flat wire motor stator with variable branch |
Family Cites Families (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US9379586B2 (en) * | 2013-04-24 | 2016-06-28 | GM Global Technology Operations LLC | Bar wound stator winding layout with long-pitched and short-pitched coils |
| CN110011450A (en) * | 2019-03-27 | 2019-07-12 | 苏州汇川技术有限公司 | Stator module and driving motor |
| CN111106692A (en) * | 2020-01-14 | 2020-05-05 | 天津市松正电动汽车技术股份有限公司 | Motor stator and hairpin motor |
| CN111478465A (en) * | 2020-05-26 | 2020-07-31 | 上海威迈斯新能源有限公司 | Flat wire stator assembly and motor |
-
2020
- 2020-05-26 CN CN202010457756.4A patent/CN111478465A/en active Pending
- 2020-09-23 WO PCT/CN2020/117206 patent/WO2021237991A1/en active Application Filing
Cited By (15)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2021237991A1 (en) * | 2020-05-26 | 2021-12-02 | 上海威迈斯新能源有限公司 | Flat wire stator assembly and motor |
| CN114079343A (en) * | 2020-08-21 | 2022-02-22 | 比亚迪股份有限公司 | Stator assembly and motor with same |
| CN113783334A (en) * | 2021-09-06 | 2021-12-10 | 恒大新能源汽车投资控股集团有限公司 | Flat wire armature winding and motor |
| CN114337009B (en) * | 2021-11-12 | 2024-04-19 | 浙江零跑科技股份有限公司 | Stator assembly, motor and electric automobile |
| CN114337009A (en) * | 2021-11-12 | 2022-04-12 | 浙江零跑科技股份有限公司 | Stator module, motor and electric automobile |
| CN114583863A (en) * | 2021-12-31 | 2022-06-03 | 华为数字能源技术有限公司 | Stator, flat wire motor, power assembly and vehicle |
| CN114337010A (en) * | 2021-12-31 | 2022-04-12 | 苏州汇川联合动力系统有限公司 | Stator module and motor |
| WO2023124509A1 (en) * | 2021-12-31 | 2023-07-06 | 华为数字能源技术有限公司 | Stator, flat wire electric motor, power assembly and vehicle |
| CN114301199B (en) * | 2021-12-31 | 2023-09-22 | 苏州汇川联合动力系统股份有限公司 | Stator assembly and motor |
| CN114301199A (en) * | 2021-12-31 | 2022-04-08 | 苏州汇川联合动力系统有限公司 | Stator assembly and motor |
| CN114583863B (en) * | 2021-12-31 | 2024-05-10 | 华为数字能源技术有限公司 | Stator, flat wire motor, power assembly and vehicle |
| WO2023201960A1 (en) * | 2022-04-22 | 2023-10-26 | 上海纳铁福传动系统有限公司 | Stator winding and motor |
| WO2024007438A1 (en) * | 2022-07-04 | 2024-01-11 | 合肥巨一动力系统有限公司 | Stator structure of hairpin motor |
| WO2024007713A1 (en) * | 2022-07-06 | 2024-01-11 | 浙江凌昇动力科技有限公司 | Stator, flat wire motor, powertrain, and vehicle |
| WO2024060734A1 (en) * | 2022-09-21 | 2024-03-28 | 丽水方德智驱应用技术研究院有限公司 | Stator assembly based on flat wire segmented skewed slot winding |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2021237991A1 (en) | 2021-12-02 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CN111478465A (en) | Flat wire stator assembly and motor | |
| CN114204708B (en) | Stator, flat wire motor, power assembly and vehicle | |
| CN114583863B (en) | Stator, flat wire motor, power assembly and vehicle | |
| CN109327094B (en) | 72-slot over 6-layer flat copper wire lap winding structure and new energy automobile | |
| CN106849435B (en) | Rotating electrical machine | |
| CN114552811B (en) | Motor stator and motor using same | |
| CN115498794A (en) | Motor stator, flat wire motor, power assembly and power device | |
| CN111555506A (en) | Motor stator and motor | |
| CN112970173A (en) | Electric machine, motor vehicle and method for producing a winding for an electric machine | |
| CN110829659A (en) | Hairpin winding type motor stator and motor | |
| CN114520560A (en) | Flat wire winding structure, stator assembly and flat wire motor | |
| CN113241869B (en) | Flat wire motor stator and flat wire motor | |
| CN215300307U (en) | Flat wire winding structure and stator and motor comprising same | |
| CN212366947U (en) | Flat wire stator assembly and motor | |
| CN114629263B (en) | Motor stator and motor using same | |
| CN216959483U (en) | Four-branch parallel flat wire winding stator and motor with same | |
| CN114825717A (en) | Stator module and motor using same | |
| CN110556935A (en) | stator assembly and motor | |
| CN114498994A (en) | Stator module and motor with field font square wire | |
| CN112583164A (en) | Flat copper enameled wire motor winding and manufacturing method thereof | |
| CN112332566A (en) | Motor stator and motor | |
| CN112436619A (en) | Motor stator and motor | |
| CN111478476A (en) | Motor stator and motor | |
| CN219875246U (en) | Flat wire wave winding, stator and motor | |
| CN220325367U (en) | Flat wire wave winding, stator and motor |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination |